Knauf Insulation Ltd

When completed, A3 New Bailey in Manchester will be one of Europe’s greenest buildings. Not only has it been designed to achieve the toughest sustainability ratings, it will also feature Europe’s largest living wall. But as with any innovative project, it presented some major challenges when it came to the specification of the rainscreen façade system. Meeting the target U-value Lester Cladding NW Ltd were responsible for the design and build of the façade. A rock mineral wool product with a thermal conductivity of 0.035 W/mK had been specified. But when conducting the calculations, they instantly ran into a problem. An insulation depth of 240mm was required to achieve the U-value of 0.15W/m2K.  Jamie Simm, Operations Director at Lester Cladding NW Ltd explained: “There was a strict external and internal boundary, so we needed to keep the façade wall build-up within those measurements. But the amount of insulation needed to meet the target U-value increased the depth of the wall, pushing it over the boundary line.” When looking for an alternative solution, the company approached Knauf Insulation’s Project Specification Team to discuss the brief. As well as meeting the thermal performance requirement, the insulation needed to comply with building regulations that ban the use of combustible materials in the external walls of certain buildings over 18m tall. It also needed to help reduce noise and meet the project’s sustainability targets.  After running 3D U-value calculations, Knauf Insulation’s Technical Support Team recommended 170mm Rocksilk® RainScreen Slab for the ventilated façade, a rock mineral wool insulation which has a thermal conductivity of 0.034 W/mK. For the Steel Frame System (SFS), they recommended 150mm OmniFit® Slab 35, a glass mineral wool insulation with a thermal conductivity of 0.035 W/mK.  This combination reduced the thickness of the wall build-up by a significant 70mm, ensuring the U-value could be met within the required parameter for the wall build-up. Simms said: “Not only did Rocksilk® RainScreen Slab offer superior U-value performance for a slimmer profile, it reduced costs across the whole build. As well as reducing the quantity of insulation required, we could use smaller helping hand brackets and thinner fire barriers for example. It was the product that steered the job through.” In addition to achieving the required thermal performance, both products are non-combustible with a Euroclass A1 reaction to fire classification. This means they will not add to the development or spread of fire, so comply with the building regulations. Rocksilk® RainScreen Slab is also British Board of Agrément (BBA) certified for use in buildings of any height and for the broadest range of thicknesses and build-ups of any rainscreen solution on the market. Mineral wool also has an open fibre matrix, which means it has sound absorbent properties. The insulation will help to reduce noise from the busy city centre location and from disturbing residents. Project complexity The choice of insulation was not the only challenge for the build. There is no template for supporting Europe’s biggest living wall. So, Lester Cladding NW Ltd needed to draw on their own extensive knowledge and expertise, as well as that of the whole supply chain to create a bespoke solution from the ground up.   One problem with this approach, was that every potential solution impacted another aspect of the façade build-up. To overcome this, Lester Cladding NW Ltd took the unusual step of arranging a meeting between representatives from eight different design and manufacturing partners. Together they discussed the whole system ‘screw by screw’.  “Getting everyone sitting around the table meant that all our manufacturing and design partners were completely engaged. They understood what we were trying to achieve, and all worked together to find the best solution.” There was one particular factor that could affect the insulation – water. While a living wall utilises planting schemes that thrive in drier conditions, a 4,000m2 living façade still requires a lot of watering – something that could introduce lots of extra moisture into the system. Knauf Insulation’s Rocksilk® RainScreen Slab has a water-repellent additive that promotes water run-off and ensures the slab will maintain its integrity. A traditional façade system prevents the insulation from getting saturated by rainwater, while the ventilation reduces the build-up of condensation and allows the insulation to dry out if it does get wet.  However, the water-repellent additive does not make the insulation waterproof, so it needed protection from the constant flow of water from the irrigation system. As a result, an additional breather membrane was installed to prevent moisture from penetrating the façade system and affecting the insulation. Sustainability A3 New Bailey has been designed to UKGBC’s Net Zero Carbon Framework and WELL Building Standard principles, as well as to achieve BREEAM Outstanding and Wired Score Platinum ratings. This meant the sustainability of the construction materials themselves was also important.  Here Knauf Insulation’s products ticked all the boxes too. Its glass and rock mineral wool insulation are made from materials that come from either naturally abundant sources or are recycled. For example, its glass mineral wool is made with upto 80% recycled glass from locally collected and processed household bottles and jars. Glass mineral wool has the lowest levels of embodied carbon of any mainstream insulation material. So, combining the use of both Knauf Insulation glass and rock mineral wool meant that the insulation solution for A3 New Bailey had less embodied carbon than a traditional all-rock insulation solution. Both products are also manufactured with ECOSE® Technology, Knauf Insulation's unique bio-based binder that contains no added formaldehyde or phenol. ECOSE® Technology is made from natural raw materials that are rapidly renewable and is 70% less energy-intensive to manufacture than a traditional binder. They also generate low levels of dust and VOCs and have been awarded the Eurofins Gold Certificate for Indoor Air Comfort. This contributes to the health of both installers and residents. Its entire glass mineral wool product range is also Declare Red List Free, which means that it does not contain any harmful chemicals on the ‘Red List’.  Thanks to Knauf Insulation’s advice, technical support and high-performance insulation solutions, Lester Cladding NW Ltd was able to deliver the rainscreen façade for A3 New Bailey – and with it, Europe’s largest living wall.

Agar Grove is a multi-award-winning development, created by 5-star housebuilder, The Hill Group for Camden Council, as part of their Community Investment Programme. With a proposed 507 new homes, once complete Agar Grove will be the largest Passivhaus development in the UK.Knauf Insulation’s glass blowing mineral wool Supafil® has been specified for Phase 1C of the project, which comprises 125 homes. We spoke to Hill’s Senior Technical Coordinator, Ben Clarke and Senior Contract Surveyor, Matthew Bricknell about the needs of the project.Prioritising real performancePassivhaus is an internationally recognised building standard, resulting in very high energy efficiency. For the residents of Agar Grove, this will mean greater thermal comfort, alongside reduced energy bills.Achieving the Passivhaus standard requires a complex balance of design factors to create high levels of insulation and airtightness. To ensure their designs would deliver in the real world, it was therefore important for Hill to specify products which would perform as well in situ as they did on paper.As Ben explains, “We chose to use blown-in insulation because of its real-world thermal performance. Installing insulation boards can sometimes mean gaps are left between them, which leads to cold bridges in the build. But that can be more easily avoided with a blown-in product.”To provide further quality assurance, Hill has appointed contractors from Knauf Insulation’s network of Approved Supafil® Installers. Trained by Knauf Insulation’s own Regional Technical Managers, they have the necessary product knowledge and expertise to ensure a quality installation.Using Supafil® will also mean that less product is wasted on-site. When rigid insulation boards are cut to size, offcuts are often discarded because they are difficult to use elsewhere. By contrast, Supafil® has a zero-waste potential. When the cavity is full any excess product remains in the insulation blowing machine hopper, ready to be installed on the next plot, and when the job is complete Supafil®’s packaging can be recycled. Ben says: “As a responsible business, Hill is always looking for ways to reduce waste on our projects wherever we can, and this solution will help us to do that”.Evidencing qualityThe Passivhaus accreditation requires Hill to demonstrate the energy efficiency of Agar Grove, which will involve data collection throughout the build and thermal imaging of the finished product. As Matt explains, “We have a significant quality assurance requirement. We need to be able to show Camden Council that we have insulated the building as specified and that’s not always a simple task – particularly with blown-in solutions which by their nature, are hidden within the cavity.”To help meet this challenge, Hill’s Approved Supafil® Installers will use Knauf Insulation’s app-based site reporting system, KinetiK®. The app allows the installer to select their site and plot number on their mobile device, photograph the elevation, and then scan each pack of Supafil® as it’s installed.Matt continues, “KinetiK® will enable us to confirm that the insulation has gone in as specified. This is essential for our client, but it also gives us confidence too. If areas are missed during an install, there are time and cost implications, so having a tool like KinetiK® will provide us with added assurance that the cavity has been fully filled.” Agar Grove will be the latest in a number of Passivhaus projects which Knauf Insulation has supported. Read more about Preston Springs, North Yorkshire here and Denby Dale, one of the first certified Passivhaus homes in the UK, here.

The new £8.5m Allam Diabetes Centre at Hull Royal Infirmary plans to treat and care for patients with diabetes and metabolic bone diseases.It also includes a significant amount of clinical research facilities supporting not only diabetes and endocrinology, but also vascular surgery, neurology and other research departments. Its curved towers flank a glass entrance, which leads to a large waiting area and reception. Spread over three storeys are consulting rooms, specialist treatment rooms, office space and changing rooms as well as a roof terrace on the second floor. Designed to achieve a BREEAM rating of ‘very good’, the thermal performance of the insulation specified for the Allam Diabetes Centre’s flat roof was hugely important. Another crucial factor was fire safety. Although the application doesn’t fall under current fire regulations banning combustible insulation, the architect specified that only non-combustible materials should be used during construction.  Main contractors Zenith Developments appointed specialist contractors Fosters Roofing to install the roof. They in turn tasked DANOSA UK with supplying all the materials for the roof construction, including the insulation. “The build-up of the Allam Diabetes Centre was a single-ply warm roof with a tapered insulation scheme to provide the fall required for rainwater run-off,” explained Steve Downey, Commercial Director at DANOSA UK. “Tapered insulation schemes are always more difficult than traditional flat roofs, so we asked Knauf Insulation for technical advice on how to achieve the required U-value of 0.18 W/m2K.” The Knauf Insulation Technical Support Team recommended Rocksilk® Flat Roof Slab. It is BBA certified for use on mechanically fixed flat roof build-ups and is suitable for all types of roof deck.  As well as excellent thermal performance, Rocksilk® Flat Roof Slab is non-combustible with the best possible Euroclass A1 reaction to fire classification. It also provides excellent sound absorption so will help reduce the drumming effect of rainfall.  Rocksilk® Flat Roof Slab contains a special water repellent additive and is manufactured using Knauf Insulation's Krimpact® Technology which provides high levels of compressive strength and durability. As the project was a tapered insulation scheme, Rocksilk® Flat Roof Slab was manufactured to order to ensure the correct fall was created. The tapered insulation scheme wasn’t the only challenge with the Allam Diabetes Centre – it also features a curved façade, which added complexity for the installation team at Fosters Roofing.  Paul Foster, Managing Director at Fosters Roofing said: “Insulation needs to be carefully cut to the exact shape of the building otherwise heat can escape making it less energy efficient. Thankfully Rocksilk® Flat Roof Slab was easy to cut and quick to install, so it wasn’t a problem.” Rocksilk® Flat Roof Slab has also been designed to knit together during installation so there are no gaps that could affect thermal, fire or acoustic performance. By using Rocksilk® Flat Roof Slab, Fosters Roofing and DANOSA UK were able to achieve the required specification for the tapered insulation scheme on the new Allam Diabetes Centre. This will contribute to the energy efficiency needed to achieve the BREEAM ‘very good’ rating. 

CHALLENGEAs part of a full exterior refurbishment, building envelope contractor, Alumet, required a new façade system that would transform and modernise the exterior of the Jubilee House building, which was originally installed in the early 1970s. Coupled with this was the requirement to improve thermal and energy efficiencies.SOLUTIONKnauf Insulation supplied its Rocksilk® RainScreen Slab to ensure optimal fire, thermal and acoustic performance. The key to Knauf Insulation securing the project was the ability to provide in depth technical support, including complex 3D heat flow modelling calculations which took into account the specific system brackets, which act as a significant cold bridge within rainscreen cladding systems.Knauf Insulation’s Rocksilk® RainScreen Slab was installed on the brick facade of the existing building, which once complete, significantly improved the U-value thus reducing the heat loss through the wall.The insulation layer is a fundamental component of any successful rainscreen cladding system and mineral wool insulation delivers a number of advantages for this type of application. Rocksilk® RainScreen Slab is a Rock Mineral Wool slab containing a water repellent additive, designed for use on masonry wall constructions and as the outer insulation layer in steel frame projects.Quick and easy to install, the product is simple to cut and the slabs knit together to create a snug fit, with no need to tape the joints as may be required with rigid foam boards – ensuring maximum acoustic and thermal performance."We wanted to turn our headquarters into a thermally efficient building and to really project a modern ‘green’ image. The Schueco Façade system, along with Knauf Insulation’s products, helped us to achieve this as well as dramatically reducing our carbon output.We have received some fantastic feedback from local residents saying how good the new façade looks and coupled with the improved thermal efficiencies, we are very pleased."- Alumet Director, Dean Walton

Ashwood House is a development of Manhattan-style apartments in the desirable Surrey commuter town, Camberley. Situated in a converted 1960s office block, developer Berkeley Homes Southern Ltd needed to ensure the 116 luxury flats were as energy efficient as possible.This was a particular concern for the properties situated above the first floor car park, which has open walls to allow adequate ventilation of exhaust fumes. As a result, the specification stipulated a U-value of 0.25 W/m²K.Chris Body, Business Development Director at RPN Ltd, the specialist sub-contractor at Ashwood House said: “We approached several insulation manufacturers to discuss the different options available. Knauf Insulation’s Rocksilk® Soffit Linerboard Standard met the brief in terms of thermal and fire performance. It can be used on uneven substrates and looks fantastic – all of which were key priorities for Berkeley Homes.”Aesthetic appealHow the insulation looked was an important part of the brief as Berkeley Homes wanted a solution that would be aesthetically pleasing. Rocksilk® Soffit Linerboard Standard features a black glass veil facing, so no additional finishing was required. This meant that RPN Ltd has been able to install the slabs perpendicular to the ring beam to create a quilted effect across the ceiling.A high-performance solutionThe other specification factors were thermal performance and fire safety. Knauf Insulation’s Technical Support Team undertook U-value calculations to determine that 130mm Rocksilk® Soffit Linerboard Standard would be required. It is manufactured from Rock Mineral Wool, has a thermal conductivity of just 0.034 W/mK and is designed to insulate structural soffits in applications such as open sided car parks.It is non-combustible with the best possible Euroclass A1 reaction to fire classification, so will not contribute to the development or spread of a fire should it occur. Rocksilk® Soffit Linerboard Standard also has excellent sound absorption characteristics so will help to ensure that residents are not disturbed by the noise of cars parking beneath their flats.Better for installersThe insulation was supplied by distributors CCF Ltd who delivered it to the site in line with the schedule of works. It was then installed by RPN’s specialist team.Rocksilk® Soffit Linerboard Standard is easier to install correctly than other insulants. The product recipe makes each slab rigid, which ensures the insulation maintains continuous contact with the substrate, preventing gaps that can reduce thermal, fire and acoustic performance.Rocksilk® Soffit Linerboard Standard is manufactured with ECOSE® Technology, Knauf Insulation’s unique bio-based binder that contains no added formaldehyde or phenol. It is made from natural raw materials that are rapidly renewable, and is less energy-intensive to manufacture than traditional binders, so it is more environmentally friendly.Products made with ECOSE® Technology are soft to touch and easy to handle. They generate low levels of dust and VOCs, and have been awarded the Eurofins Gold Certificate for Indoor Air Comfort. This means they are kinder to the installers who use them too.A safe solutionUltimately, using Knauf Insulation’s Rocksilk® Soffit Linerboard Standard means the Ashwood House car park ceiling not only looks aesthetically pleasing, but it helps to meet the increasing demand for non-combustible insulation in car parks too.

ChallengeTargeted with achieving a minimum BREEAM rating of Excellent and with only a short window of time to complete the project, Associated Architects, who designed the building, needed insulation products that would meet strict thermal and environmental requirements – as well as a manufacturer that could offer quick turnaround times and a high level of technical support.SolutionWith the help of Knauf Insulation specification manager, Marc Lawson, a through wall solution using 5,000m² of Knauf Insulation’s 100mm Rocksilk® RainScreen Slab – a rock mineral wool slab containing a water repellent additive, specifically designed for rainscreen cladding systems was used. It is quick and easy to install and is simple to cut and fit around brackets. The slabs knit together with no need to tape the joints – ensuring maximum acoustic and thermal performance, with no air gaps. Knauf Insulation’s Rocksilk® RainScreen Slab is also non-combustible and has the highest Euroclass A1 reaction to fire classification, as well as excellent sound absorption performance.To further enhance the thermal properties of the element, 10,500m² of Knauf Insulation’s Rocksilk® Flexible Slab 100mm, was installed in two layers within the SFS system. Designed to friction fit between metal studs, rafters and joists, Rocksilk® Flexible Slab is a multi-purpose rock mineral wool insulation slab, which provides excellent thermal and acoustic performance.Chris Kinman, Senior Design Manager at Willmott Dixon commented; “Knauf Insulation’s products are easy to handle and cut which makes them very easy to use on site. The first phase of the project has gone well, and the architect has adopted a similar approach to Phase 2 - which is testament to the excellent performance so far. Overall, we have been very impressed by the help and support we have received from Knauf Insulation on the project, and we have since recommended them to other colleagues."Rocksilk® RainScreen Slab and Rocksilk® Flexible Slab rock mineral wool products are made with ECOSE® Technology, a formaldehyde-free binder derived from rapidly renewable materials, instead of traditional petro-based chemicals used in other insulation. Additionally, ECOSE® Technology is up to 70% less energy intensive than traditional binders.

ChallengeFor the air traffic controllers at Birmingham Airport, concentration is critical to ensuring the safety of the hundreds of passenger jets that take off and land every day. Studies show office workers lose concentration when noise levels hit 55dB; however, the sound of just one medium-sized aircraft descending at 1,000ft is 70dB.SolutionWith this in mind, noise reduction was an essential factor in the specification of the insulation for the 105ft air traffic control tower. The airport’s developers consulted Knauf Insulation’s Technical Support Team for advice. The Technical Support Team recommended Rocksilk® RainScreen Slab, a non-combustible Rock Mineral Wool insulation designed for use in high-rise rainscreen façade systems.Mineral Wool insulation has superior acoustic performance because of its open structure, which traps sound between the individual strands and turns it into heat energy.Rocksilk® RainScreen Slab is quick and easy to install and adapts to minor imperfections in the substrate. Slabs are flexible and knit together eliminating air gaps for maximum acoustic and thermal performance, making it perfect for use on the curved walls of the funnel shaped control tower. The same level of acoustic performance could not have been achieved with rigid foam boards, which have closed cell structures that offer virtually no sound absorption. Rigid foam boards are also more prone to air gaps, reducing acoustic performance further.As well as excellent acoustic and thermal performance, Rocksilk® RainScreen Slab is non-combustible with Euroclass A1 reaction to fire classification. This means it will not contribute to the spread or development of fire should it occur.Another factor in the specification of Rocksilk® RainScreen Slab was sustainability. It is manufactured with ECOSE® Technology, Knauf Insulation’s unique bio-based binder, which contains no added formaldehyde or phenol. It is made from natural raw materials that are rapidly renewable, and is 70% less energy-intensive to manufacture than traditional binder, so it is more environmentally friendly. Products made with ECOSE® Technology generate low levels of dust and VOCs, and have been awarded the Eurofins Gold Certificate for Indoor Air Comfort.Thanks to Rocksilk® RainScreen Slab the air traffic controllers at Birmingham Airport can enjoy a quieter, warmer, safer and more sustainable workplace."Acoustic protection, energy performance, fire safety and sustainability were all crucial factors taken into account during the design of the air traffic control tower and so all materials specified with the project needed to meet these multiple requirements. We are extremely pleased with the building."Will Heynes, Birmingham Airport’s Development Director

Central M40, a 70 acre industrial estate situated off J11 of the M40 in Banbury, comprises six warehouses totalling over 1 million sq ft of accommodation – equivalent to roughly 17 football pitches. The estate was developed speculatively by db Symmetry*, who specified CA Group’s robust Twin-Therm® Built-up Roof and Wall systems.A key component of the Twin-Therm® building envelope system is Therma-Quilt, a bespoke high-performance Glass Mineral Wool insulation. It is manufactured by Knauf Insulation specifically for CA Group and is the result of a long standing partnership between the two companies.Therma-Quilt is ideally suited for non-residential cladding applications. It offers outstanding performance and functionality available in different thicknesses to support the Twin-Therm® system, delivering enhanced thermal U-values as low as 0.09W/m2K. It is non-combustible with a Euroclass A1 Reaction to Fire Classification, meaning it will not contribute to the development or the spread of a fire.Therma-Quilt is also a high-performing acoustic insulation. In Twin-Therm® roof applications, it helps reduce the drumming effect of rainwater, while in Twin-Therm® wall applications, it aids with sound reduction and can minimise the reverberation of internal sound when used in conjunction with perforated metal liner sheets. Therma-Quilt has been developed with water resistance in mind and uses materials that help prevent water ingress.The Twin-Therm® system has been designed with sustainability in mind and Therma-Quilt is no exception. Knauf Insulation’s Glass Mineral Wool products contain up to 80% recycled materials. This saves on virgin raw materials and energy demands, cuts carbon emissions, and reduces waste going to landfill.It is manufactured with ECOSE® Technology, Knauf Insulation's unique bio-based binder that contains no added formaldehyde or phenol. It is made from natural raw materials that are rapidly renewable and is 70% less energy-intensive to manufacture than traditional binder, so it is more environmentally-friendly.Products made with ECOSE® Technology are soft to touch and easy to handle. They generate low levels of dust and VOCs and have been awarded the Eurofins Gold Certificate for Indoor Air Comfort.In total, more than 70 tonnes of Therma-Quilt insulation were used on the six megasheds on the Central M40 development. While the industrial estate was built speculatively, its strategic location has previously attracted premium occupiers including Hellofresh, Prodrive Motorsport, TVS Supply Chain Solutions and Rinkit.Thanks to the Twin-Therm® system with its Therma-Quilt insulation, the warehouses have achieved BREEAM ‘Very Good’ ratings, while the businesses using them will enjoy more comfortable, warmer and safer working environments – and lower energy costs. *db Symmetry has rebranded as Tritax Symmetry

The Chilterns Lifestyle Centre in Amersham will feature a range of leisure, sports and community facilities. As each of the activities taking place will require different indoor temperatures – warm or cool – to keep users comfortable, a high-performing insulation solution was essential.Thermal performance wasn’t the only factor in insulation choice for specialist façade contractor Teampol. At just 14m high, the Chilterns Lifestyle Centre doesn’t fall under current fire regulations banning combustible insulation. But non-combustibility was still a key consideration in installing 2,300m2 of Knauf Insulation’s OmniFit® Slab 35 and Rocksilk® RainScreen Slab.“The original specification was for a combustible phenolic insulation,” said Scott Millins, Quantity Surveyor at Teampol. “But there’s always that concern at the back of my mind of ‘what if the worst happened?’ so I will only use non-combustible insulation whatever the height of the building. Plus, there’s a very real possibility that regulations may change again, and I don’t want my projects to need costly remedial work further down the line.”“I approached several manufacturers for a non-combustible alternative. They weren’t able to do the calculations quickly and couldn’t meet the U-value required without increasing the depth of the rainscreen insulation from 80mm to 120mm, which would have impacted the whole design.”By this point, finding a solution was critical, otherwise the entire project would be delayed. Millins approached Knauf Insulation’s Specification Team for support and product advice stressing the need for a fast turnaround. Within 24 hours, the Technical Support Team had conducted 3D U-value calculations and a condensation analysis.They recommended 150mm OmniFit® Slab 35 for the steel frame stud with Rocksilk® RainScreen Slab for the façade. Crucially, this combination meant they were able to meet the U-value of 0.22 W/m2K and keep to the original 80mm insulation depth specified for the rainscreen.“Knauf Insulation were fast, responsive and helpful,” explained Scott. “From our initial conversations, it was clear they had the technical expertise, and this was backed up by an extremely quick turnaround for all the supporting calculations that I needed to move forward with the job.”Both OmniFit® Slab 35 and Rocksilk® RainScreen Slab offer exceptional levels of thermal performance. They are non-combustible with the best possible Euroclass A1 reaction to fire classification so will not contribute to the development or spread of fire should it occur. Rocksilk® RainScreen Slab is BBA certified for use at any height.OmniFit® Slab 35 and Rocksilk® RainScreen Slab also have excellent sound absorption characteristics which will help ensure that any sports and community activities taking place inside don’t disturb local residents.As well as Knauf Insulation’s technical advice and product performance, the consistency and quality of the two products have impressed Millins and the Teampol installation team.“Installation of both OmniFit® Slab 35 and Rocksilk® RainScreen Slab has gone extremely smoothly. They’re both quick and easy to fit and it helps that these Mineral Wool products from Knauf Insulation are nice and soft – our installation team love working with them,” added Millins.This softness is thanks to the ECOSE® Technology, Knauf Insulation's unique bio-based binder which contains no added formaldehyde or phenol. Products made with ECOSE® Technology are also easy to handle, generate low levels of dust and VOCs and have been awarded the Eurofins Gold Certificate for Indoor Air Comfort.As well as being kind to installers, ECOSE® Technology is made from natural raw materials that are rapidly renewable and is 70% less energy-intensive to manufacture than traditional binders, so it is kinder to the environment too.Thanks to Knauf Insulation’s rapid response and technical support, Teampol was able to meet the thermal requirements for the Chilterns Lifestyle Centre project using non-combustible insulation – all while keeping to the tight build schedule.

Located on the former BBC site, Circle Square in Manchester aims to create a vibrant neighbourhood comprising city living apartments, prime office, retail and leisure space. Phase two of the development saw the construction of No’s 5 to 8, four buildings totalling 677 luxury flats with private dining, resident lounge, gym and cinema, as well as commercial space. Specification requirements FK Group were appointed to design and install a bespoke façade solution which meant they were responsible for specifying the insulation. There were three main performance factors that needed to be considered.  Firstly, the insulation had to be non-combustible to ensure compliance with building regulations in England and Wales, which ban the use of combustible materials on the external walls of certain buildings over 18m tall.  The second consideration was thermal performance. “When you’re designing a bespoke façade solution, accurate thermal modelling is essential because there are so many variables that can affect its energy efficiency,” explained Ben Hufton, Associate Design Director of FK Group. “One of the reasons we work with Knauf Insulation so much is because of their technical support. They always conduct 3D U-value calculations for rainscreen façade projects, so we know the insulation will deliver the performance we need to achieve.” This enhanced level of accuracy is one of the main benefits of 3D U-value calculations over other calculation methods, because it ensures a building’s real world thermal performance matches its initial design.  To achieve the required U-value of 0.28 W/m2K, the Knauf Insulation Technical Support Team recommended 200mm Rocksilk® RainScreen Slab for the external cavity. This has a thermal conductivity of just 0.034W/mK. Rocksilk® RainScreen Slab is manufactured from Rock Mineral Wool and is BBA certified for use in high rise buildings for the broadest range of build-ups of any rainscreen solution on the market. It is also non-combustible with the best possible Euroclass A1 reaction to fire classification. This means it will not contribute to the development or spread of fire should it occur. The final specification factor was acoustic performance due to the site’s busy city centre location.  FK Group conducted offsite acoustic tests to ensure that the build-up met the requirements of Approved Document E. The Mineral Wool insulation contributes significantly to the acoustic performance of the build-up thanks to its open structure. Sound waves are trapped between the individual strands of Mineral Wool and turned into heat energy. This will help to reduce noise from surrounding roads, ensuring residents can enjoy peaceful homes. Other performance factors As it has been developed for external applications, Rocksilk® RainScreen Slab contains a water repellent additive which is combined with a fibre matrix that promotes run-off. This ensures it can resist moisture ingress whilst maintaining its excellent vapour permeability. The physical characteristics of the fibres are unaltered if they get wet. Therefore, the thermal properties of Rocksilk® RainScreen Slab are not affected by exposure to moisture and the product will perform as expected once it has dried out. The product is easy to install correctly thanks to superior robustness and durability, allowing it to be manoeuvred easily into place. Its natural flexibility means it adapts to minor imperfections in the substrate, while slabs interlock, eliminating air leakage that could reduce thermal and acoustic performance. Rocksilk® RainScreen Slab is also manufactured with ECOSE® Technology, Knauf Insulation’s unique bio-based binder that contains no added formaldehyde or phenol. It is made from natural raw materials that are rapidly renewable, and is 70% less energy-intensive to manufacture than traditional binder, so it is more environmentally-friendly. Products made with ECOSE® Technology generate low levels of dust and VOCs (volatile organic compounds) and have been awarded Eurofins Indoor Air Comfort (Gold) certification. Circle Square will give residents access to everything they need from a community district – just as Knauf Insulation’s Rocksilk® RainScreen Slab ticked all the boxes for FK Group.

Four years ago, sustainable developer Citu set out to create homes 10 times more energy efficient than typical UK houses. To do this, the company invested in a state-of-the-art production facility where all the components for its properties are built offsite.Thermal performance is critical to energy efficiency. Citu wanted to go far beyond the regulations to achieve wall build-ups with an extremely low U-value of just 0.10W/m2K. This is at least three times better than the U-value achieved in most new build homes and fifteen times better than older houses.Adding offsite capabilityCitu turned to Knauf Insulation for advice and support in developing the offsite capability required for this level of thermal performance. Knauf Insulation’s Technical Support Team undertook extensive calculations and recommended the Blowing Plate Insulation System to install Supafil® Frame – a high performance, non-combustible blowing wool.Supafil® Blowing Wool lends itself to offsite production because it completely fills the cavity, without any voids even around complex penetrations – something that can occur when insulation slabs or rolls are cut to size. It is also a dry process, so operatives are not exposed to any harmful chemicals and it doesn’t require a dedicated production line.Instead, the system comprises a blowing machine and a filling plate. The system is modular allowing for phased investment. Citu opted to install the blowing machine in phase one, which allowed them to manually fill the panels. Phase two saw the addition of the blowing plate, semi-automating the process.Supafil® Frame can be run by a single operator, fits easily into the existing production line, and can even be moved quickly and swiftly to other areas in the manufacturing facility depending on Citu’s volume capacity requirements.Knauf Insulation’s Technical Support Team provided full training and support during each phase of installation.Insulating the panelsCitu homes are manufactured from wooden panels with a 300mm cavity. The blowing plate is positioned over the panel completely covering the cavity. Supafil® is then blown into the wooden frame to the specific parameters of each panel. All cavities are filled to the correct thickness; something that has been carefully calculated and tested by the Knauf Insulation Technical Support Team to ensure settlement does not occur. And because the machine is programmed to install the exact quantity of insulation required, there’s no waste.Supafil® is a high performance Blowing Wool. It is non-combustible with Euroclass A1 reaction to fire classification as well as providing excellent thermal and acoustic performance. It contains a silicone-based additive to ensure it is water repellent.As well as providing excellent thermal performance, Supafil® has great sustainability credentials. Knauf Insulation’s Glass Mineral Wool contains up to 80% of recycled content. This reduces the amount of virgin materials used and prevents around 60,000 tonnes of glass a year (350 million bottles) from going to landfill or polluting the environment. Knauf Insulation has also invested in advanced compression packaging. This means there’s less packaging used, so fewer lorries on the roads leading to a reduction in transport carbon emissions. All of which helps to support Citu’s goal that every home should be carbon zero to manufacture.By combining modern methods of construction with the very highest levels of thermal performance, Citu and Knauf Insulation are creating homes that reduce energy consumption and carbon emissions – homes that are fit for the future.

ChallengeThe boundary between adjoining properties has always been assumed to be an area of neutral heat loss. However, research undertaken by Leeds Metropolitan University, MIMA (the Mineral Wool Insulation Manufacturers’ Trade Association), BRE (Building Research Establishment) and Knauf Insulation has revealed that a significant amount of heat is actually lost through uninsulated cavity party walls.It is estimated that there are 7.4million existing party walls that have been built with a cavity across the UK.Although these walls provide fire and acoustic separation to meet the requirements of relevant building regulations, the thermal performance of a party wall had not previously been considered.Knauf Insulation has provided solid evidence that its Supafil® Party Wall glass mineral wool blowing insulation is a reliable way of eliminating party wall bypass and so City West Housing Trust, a Salford based housing association, has installed the product as part of a pilot scheme to a number of its properties.Working alongside Bridgewater Surveyors and others, City West wanted to improve the energy efficiency of their tenants' properties and are continually looking for other ways to reduce energy costs and consumption. Knowing that by insulating the cavity party walls of properties could lower energy bills for their tenants they embarked on the trial project – with the aim of a possible roll out across other areas in the North West.After approaching Knauf Insulation for advice, City West and Bridgewater Surveyors settled on a reliable solution: Knauf Insulation’s Supafil® Party Wall insulation.SolutionSupafil® Party Wall prevents heat loss through party separating cavity walls by fully filling the cavity. Supafil® Party Wall is an in-situ formed unbonded, non-combustible glass mineral wool. Knauf Insulation have now completed an extensive research programme to develop a proven methodology for installation into existing homes to add to the product’s use in new build applications.As well as being an excellent thermal insulant, Supafil® Party Wall insulation also has good sound absorption characteristics which help to ensure that when a party wall is upgraded, it complies with the requirements of Approved Document Part E of the Building Regulations - which is designed to protect occupants from noise in adjoining rooms or buildings.As part of the Salford project, houses were tested before and after the installation took place. The reduction in the heat loss was equivalent to an improvement in the effective U-value of the party wall of at least 0.5 W/m2K. This shows there is a significant beneficial impact for tenants in fully filling cavity party walls with Supafil® Party Wall Insulation.Supafil® Party Wall insulation fitted into City West’s obligation to maintain a greener environment as the product conserves energy and reduces the emissions of the major greenhouse gas, CO2. The energy and CO2 emission saved by the product in use vastly outweighs those generated in its manufacture. Supafil® Party Wall has a generic BRE Green Guide Rating of A+ and has zero Ozone Depletion Potential and zero Global Warming Potential.When completed, the trials will measure the extent of customers’ energy bill savings – estimated to be up to £90 a year – as well as the amount of carbon emissions that could be reduced."We are committed to ensuring our properties are as energy efficient as possible and along with Supafil® Party Wall insulation we have installed cavity and loft insulation to our portfolio of properties."Gary Vaughan – Head of Sustainability & Supply Chain, City West

Approximately 23,000m2 of Knauf Insulation’s new FactoryClad Roll 35 is being used to insulate the roof of the new Co-op Live – helping to create one of the world’s most energy-efficient indoor arenas.Manchester is known for its rich cultural heritage, but now Co-op Live, the UK’s largest indoor arena, aims to put the city on the world stage for sustainability too. It is designed to be a 100% electrically powered venue and features 6,400m² solar panels as well as air source heat pumps – so a highly efficient building fabric was essential to ensure they operate effectively.With Knauf Insulation’s St Helens manufacturing plant based just 30 miles down the road, the company was a perfect partner for sub-contractor Lindner Prater, which was responsible for constructing the arena’s 12,000m2 twin roof. Lindner Prater contacted Knauf Insulation’s Specification Team to discuss the project’s insulation requirements.Finding a partnerThe Co-op Live roof comprises two independent roof systems, the lower cassette and the upper standing seam roof, working in conjunction with one another to meet the high-performance requirements of the arena. Each element of the build was meticulously examined to ensure the products installed achieved on all fronts.Karl Moxon, Associate Director at Lindner Prater, described the process of selecting an insulation partner:“For the upper standing seam roof, there were a number of key factors required for the insulation. Firstly, thermal performance. The standing seam roof is a tapering built-up system onto a flat concrete slab, and we needed to meet the overall performance requirements taking into consideration the unique twin roof design.“Secondly, for a venue of this size and with our own policies ensuring that the highest standards of fire safety are achieved, it was imperative that we sourced an insulation material that was non-combustible. In addition, the products used had to be sustainable and our key project partners had to align to the sustainable goals of the project.“We needed a partner ready to exceed in technical excellence and prepared to innovate when required. Knauf Insulation exemplified this in its approach to Co-op Live.”Creating a new productThe design intent was to use a 0.035W/mK lambda mineral wool insulation installed in two layers at a range of depths between 220mm and 440mm within the built-up metal roof. With the tapered void between the deflecting flat slab and the standing seam finish, the product also needed to be manufactured in five thicknesses ranging between 60mm and 220mm.After reviewing several options with the Lindner Prater team, Knauf Insulation agreed to develop a new glass mineral wool product, FactoryClad Roll 35, specifically for the Co-op Live project.FactoryClad Roll 35 is a glass mineral wool insulation that is naturally non-combustible with the best possible Euroclass A1 reaction to fire classification. Because it is made of mineral wool, it also acts as a sound absorbent lining, so can help control the reverberation of internal sound. It comes in five thicknesses between 60 and 220mm and is manufactured at a width of 1,200mm for speed of fitting. It also has a high tear strength which ensures its durability and ease of handling during installation.Reducing environmental impact“Of course, the product’s thermal and fire safety performance were only part of the equation,” said Karl. “Sustainability sits at the heart of the Co-op Live project, so any construction products we proposed also had to meet the most rigorous sustainability standards – and here Knauf Insulation ticked all the boxes.”Reducing the embodied carbon of its products has long been a priority for Knauf Insulation. Fifteen years ago, it developed ECOSE® Technology, its unique bio-based binder that is used in the manufacture of most of its insulation, including FactoryClad Roll 35. It contains no added phenol or formaldehyde and is less energy-intensive to manufacture than traditional binders.Products manufactured with ECOSE® Technology have been awarded Eurofins ‘Indoor Air Comfort’ Gold. This is a European-wide accreditation for low-VOC products that go beyond the legislated minimum standards and contain no added formaldehyde or phenol. Knauf Insulation’s entire glass mineral wool range is also accredited as Declare 'Red List Free’, which means it doesn’t contain any harmful chemicals on the ‘Red List’.Its glass mineral wool insulation is made from up to 80% recycled content, mainly glass bottles and jars collected from the local area. In other words, the equivalent of approximately 123,000 empty glass wine bottles is being used to insulate the new Co-op Live arena roof.The flexible structure of mineral wool insulation allows it to be compressed during the packaging process. To maximise this potential, Knauf Insulation has invested in advanced compression packaging so there’s more product per pack and per pallet. This reduces the number of trucks on the roads and associated transport-related carbon emissions. It also reduces the amount of plastic packaging required per m2 of insulation.As well as prioritising the use of sustainable products, Co-op Live has a zero-waste direct to landfill policy. Here Knauf Insulation scores highly too. Its product packaging film is made from up to 50% Post-Consumer Recycled (PCR) plastic, mainly plastic milk bottles, that would otherwise have gone to landfill. It can also be recycled through the development’s own recycling schemes once the products have been unwrapped.Thanks to its commitment to sustainability and the development of FactoryClad Roll 35, Knauf Insulation proved to be the perfect insulation partner for Lindner Prater. And it will play a key role in helping Co-op Live achieve its ambition of becoming one of the most sustainable and energy-efficient indoor arenas in the world.

CHALLENGEAn ambitious project, and one of the first certified PassivHaus homes in the UK - the Denby Dale PassivHaus in West Yorkshire, had to to use 90% less energy for space heating than the average UK dwelling – with a space heating need of only 15 kWh/m2/ year. The three-bedroom property is the first UK Passivhaus to be built in a traditional style using cavity wall construction and had to be built to a tight budget of £141,000.SOLUTION“We decided to go down the cavity wall path and arrived at the design for several reasons including: planning restrictions, thermal store, cost, and maybe most important of all, buildability,” explains Bill Butcher, Project Leader.Excellent performing insulation is obviously fundamental to Passivhaus construction and the Denby Dale house has 300mm Knauf Insulation DriTherm® Cavity Slab 32 in the walls, 500mm Knauf Insulation Loft Roll 44 in the roof void (both of which incorporate ECOSE® Technology) along with 225mm of high-performing Polyfoam® Floorboard Standard* insulation in the floor.“We’re fully filling the cavity with glass mineral wool insulation for the walls above ground, because it helps minimise air movement in the cavity and offers greater flexibility, fitting snugly around the ties, openings and imperfections of the masonry surface.” comments Bill Butcher.Economics, performance, availability, ease of fitting and reducing thermal bypass were all among the benefits of the Knauf Insulation products chosen.*No longer sold through Knauf Insulation.BENEFITSGlass Mineral Wool was specified over rigid insulation to ensure a tight thermal fit. Knauf Insulation DriTherm® Cavity Slabs are flexible enough to eliminate air gaps and prevent heat loss due to their inherent ability to knit together at joints between the slabs. If rigid insulation is used and fitted badly with too many gaps, air movement around and between the insulation boards is increased, which can drastically reduce its insulation value.Knauf Insulation DriTherm® Cavity Slabs are BBA Certified for all exposure zones and formally guaranteed for 50 years to prevent the transmission of liquid water from the outer masonry leaf to the inner masonry leaf.In addition to its thermal performance glass mineral wool also has other sustainable features. In manufacture it uses a high content of recycled glass bottles and requires less overall energy consumption than some alternative products, resulting in less carbon emissions. In addition, it can be recycled at the end of a building’s life and has zero GWP and zero ODP. ECOSE® Technology further extends these established green credentials as it is manufactured with 70% less energy than traditional binders and the products contain no dyes or added formaldehyde – providing the ideal solution to the eco-friendly house.

ChallengeBREEAM ‘excellent’ was a key requirement for this project. As a European centre for bioenergy research, Aston University was keen to maintain the sustainable ethos of EBRI within the building itself and make improvements wherever they could be accommodated.SolutionKnauf Insulation worked closely with Associated Architects to specify the correct rainscreen insulation product to meet the necessary requirements.The insulation layer is a fundamental component of any successful rainscreen cladding system and rock mineral wool insulation delivers a number of advantages in this type of application. Knauf Insulation’s Rocksilk® RainScreen HD Slab in a bespoke 120mm size was ideal for the project, delivering exceptional thermal, fire and acoustic performance.Insulation was specified with the help of Knauf Insulation’s regional specification manager Marc Lawson and Technical Advice and Support Centre (TASC). To successfully mitigate the differing dimensions of the constituent elements of glass channel, blockwork substrate and insulation, a smaller than standard slab size was specified, allowing for the edge of the slabs to align behind the joints in the glazed façade, providing an aesthetically pleasing appearance.The early involvement of the regional specification manager in the project and their relationship with the architects and client at the concept stage, made for a very smooth delivery and ensured the required U-value of 0.22W/m2K would be achieved without the need to re-design elements later in the project.Knauf Insulation’s Rock Mineral Wool products deliver exceptional environmental performance and are manufactured using the innovative ECOSE® Technology - a revolutionary, bio-based, formaldehyde free binder technology that is based on rapidly renewable materials, rather than petro- based chemicals. This was a key reason to the insulation being specified for this exceptionally sustainable project."Sustainability is at the very heart of all we do at Aston University. We are delighted with the results: an iconic building that conducts sustainable research in a truly sustainable environment." Alan Charters, Executive Director of Capital Development at Aston University

Factory International will transform the former Granada Studios into a world-class cultural and arts venue in the heart of Manchester. It features The Hall, a large auditorium, and The Warehouse, a flexible multi-purpose space that is taller than four double-decker buses, longer than a jumbo jet and can accommodate 5,000 visitors.Alongside the two public events spaces are The Towers, which house the ground floor entrance foyer, five floors of office space and a plant room at the top of the building. Noise reduces productivity by 66% so when it came to specifying the soffit insulation for The Towers, the architect wanted a solution that would limit airborne sound transfer and reverberation.The insulation would be on display, so aesthetics was also important, and because Factory International will cater for large crowds of people, the chosen solution needed to be non-combustible.Meeting the briefThe architects specified Knauf Insulation’s 50mm Heraklith® Tektalan A2 SmartTec for the soffit insulation in the ground floor foyer of the Warehouse area, main feature staircase, offices and plant room of The Towers.Heraklith® Tektalan A2 SmartTec is a cement-bonded wood wool panel combined with a rock mineral wool insulation core. Both materials have an open structure that naturally absorbs the kinetic energy of sound waves, turning them into heat. It is also non-combustible with an Euroclass A2-s1,d0 reaction to fire classification.Crucially, the Heraklith® wood wool range is also designed for applications where aesthetics is important because the panel is on display. It features bevelled edges and comes in nature tone as standard, or can be ordered in any RAL colour upon request, to create a stylish, uniform finish.To compliment the design schemes in the different zones across the building, contractors, Mansell Building Solutions, ordered the panels in a combination of midnight blue, pebble grey, anthracite and black.Scheduling deliveriesAs the Factory International site is quite compact, there was little room available for storage. So, Knauf Insulation worked closely with distributor Encon Insulation to ensure the insulation was held in stock. Smaller deliveries were then made in line with Mansell Building Solutions’s schedule of works. This ensured that the insulation could be installed as soon as it arrived on site.The product is quick and easy to install. Panels are fixed into position by installing Heraklith® DDS Plus Concrete Screws into each corner and the centre of the panel. The fastener heads have a patented wood wool texture to enhance the finished appearance.Ultimately, installing Heraklith® Tektalan A2 SmartTec onto the soffits in The Towers and the ground floor foyer of the Warehouse not only compliments the design scheme and contributes to fire safety, but it will enable the team behind the events at Factory International to enjoy a quieter working environment too. 

ChallengeThe much acclaimed architect Zaha Hadid created the design for the Riverside Museum, which has already been dubbed ‘Glasgow’s Guggenheim’.The new riverside Museum provides an exciting new home for Glasgow’s transport collection. The development has a riverside location on a site where the River Clyde meets Glasgow’s other main river the Kelvin, and is adjacent to Glasgow Harbour.The dynamic new Riverside Museum displays Glasgow’s rich industrial heritage, which stems from the River Clyde. The Tall Ship is berthed alongside the Museum, creating a fantastic experience in this stunning setting.The brief for design and build roofing specialist Varla (UK) Limited was to find a flexible insulation that could meet the demanding U - value of 0.20 W/m2K that was continuous over both the walls and the complex 18,000 square metre roof. The Glasgow Museum of Transport is a complex, heavily engineered design and was the first major UK project for the renowned architect Zaha Hadid.Specialist Roofing contractor, Varla (UK) Limited started the search for a suitable material by contacting many insulation suppliers and holding supplier seminars at Varla’s Chester offices, challenging suppliers to propose a solution to meet the demanding specification for this unique project.SolutionVarla (UK) Limited chose to use Knauf Insulation’s FactoryClad Roll 32, a flexible insulation that meets the demanding U-value of 0.20 W/m2K across both the roof and walls.Rigid foam boards were ruled out early on, as they could not be fitted to the building’s complex curves. There was also a limited cladding zone that could not be altered. Many types of insulation were considered, but glass mineral wool roll provided the best thermal efficiency. The key to Knauf Insulation’s products being specified on this project was its ability to provide in-depth technical support, including complex three-dimensional heat flow modelling calculations. This allowed Knauf Insulation to produce a solution that met all of Varla’s insulation requirements by using a double layer of 100mm Knauf Insulation FactoryClad Roll 32. This is a flexible, lightweight roll of resilient Glass Mineral Wool with exceptionally high tear strength and a thermal conductivity of just 0.032 W/mK.In addition, Knauf Insulation FactoryClad Roll 32 is ideal for limiting the spread of fire since it holds a Euroclass A1 reaction to fire classification for non-combustibility and will not burn. Nor will it give off toxic smoke or suddenly ignite in a fire due to ‘flashover’. For public buildings such as this, superior fire performance is crucial.Once Varla (UK) Limited had decided on Knauf Insulation, it leaned on them heavily for technical support, utilising the unique 3D heat loss calculation support service, which ensured the correct product thickness was specified to meet the demanding project requirements.

Gulson Road is a new state of the art student accommodation block in the heart of Coventry’s university district. With 462 rooms, shared study areas, a common room, gym and staff management suite all set over eight storeys, fire safety was of the utmost importance.With this in mind, the architect, Stride Treglown, specified that Rock Mineral Wool should be used to insulate the rainscreen façade to comply with building regulations, which ban the use of combustible materials on all buildings over 18m tall.Knauf Insulation’s Technical Support Team undertook 3D U-value calculations on behalf of main contractors Robertson Construction and recommended 150mm Rocksilk® RainScreen Slab to achieve a U-value of 0.18W/m2K.Rocksilk® RainScreen Slab has a thermal conductivity of just 0.034W/mK. It is non-combustible with the best possible Euroclass A1 Reaction to Fire Classification rating, so will not contribute to the development or spread of fire should it occur. It is BBA certified for use in high rise buildings and the broadest range of build-ups of any rainscreen solution on the market.As well as exceptional thermal performance and fire safety, Rocksilk® RainScreen Slab provides high levels of sound absorption.Rocksilk® RainScreen Slab is easy to install correctly. The slabs interlock and adapt to minor imperfections in the substrate eliminating air leakage, which can reduce thermal and acoustic performance. It is also robust and durable with a water repellent additive to preserve its integrity while exposed during construction.Rocksilk® RainScreen Slab is manufactured with ECOSE® Technology, Knauf Insulation’s unique bio-based binder that contains no added formaldehyde or phenol. It is made from natural raw materials that are rapidly renewable, and is 70% less energy-intensive to manufacture than traditional binders, so it is more environmentally-friendly.Products made with ECOSE® Technology generate low levels of dust and VOCs (volatile organic compounds) and have been awarded the Eurofins (Gold) certificate for Indoor Air Comfort.Thanks to the enhanced thermal and acoustic performance from Knauf Insulation’s Rocksilk® RainScreen Slab, students at Gulson Road will enjoy warm, quiet, safe and sustainable flats to study, socialise and sleep in.

Knauf Insulation is delighted to have been appointed as preferred insulation supplier to innovative new housebuilder, HarperCrewe. In addition to supplying their Supafil® and Loft Roll glass mineral wool solutions, Knauf Insulation will provide support to HarperCrewe’s team, from the design phase through to installation. Their first collaboration is already underway at The Steadings, HarperCrewe’s new neighbourhood of homes in Cirencester, and future projects look set to benefit from the same end-to-end support service. John Nunney, Commercial Director for HarperCrewe explains, “Outstanding build quality is at the forefront of our approach but, as a smaller business, it can be harder to get first pick at the best products on the market. Supafil® 34 is in demand because it’s straightforward to install and it works as it’s supposed to, so our relationship with Knauf Insulation is very important to us. It means we have consistent access to reliable, high-quality products that form an essential part of our builds.” Working closely with HarperCrewe’s design team from the very beginning of the process, Knauf Insulation’s Housing Specification Managers have already helped the business to navigate the latest updates to Part L of the Building Regulations. Advice on SAP calculations and detail drawings, as well as guidance to optimise their insulation specification have helped HarperCrewe’s team meet the new requirements, without compromising on their existing priorities. Of course, getting the specification right is just the first step, so Knauf Insulation’s support will continue well beyond the design phase. As projects move into construction, Housing Specification Managers will attend site start meetings and discuss each plot with HarperCrewe’s team. This will allow them to identify the right time for installation to take place, preventing the product’s performance from being compromised by subsequent construction work. When that time comes, Knauf Insulation’s Regional Technical Managers will be on-hand to offer advice to site teams as needed and ensure a smooth installation.  For projects using Supafil® insulation, HarperCrewe will have access to a list of Approved Supafil® Installers, who have the necessary training and experience to deliver a high-quality installation. Those installers will in turn have access to KinetiK®, Knauf Insulation’s app-based site reporting system that creates an instant digital record of installations.  Using the app on their mobile device, the installer will simply select their site and plot number, take a photo of each elevation, scan the unique QR code on each pack of Supafil®, and install the product as specified. HarperCrewe will then receive confirmation that the specified product has been installed. Not only will this provide additional confidence in the specification integrity, it will also streamline HarperCrewe’s reporting process, giving them more time to focus on the ‘big picture’ aspects of their development. 

Hockley Mills is a prestigious mixed-used development comprising 395 apartments and 28,000 sq ft of commercial space with a new entrance to Birmingham’s Jewellery Quarter train station – and undercroft parking for 116 cars. Car parks present a unique set of challenges when it comes to the specification of soffit insulation and Hockley Mills was no exception. There were several factors to consider. As well as thermal performance, fire safety was essential – so the insulation had to be non-combustible. It also needed to reduce sound transfer to ensure that residents and workers in the building would not be disturbed by vehicle noise from the car park below.  As well as meeting the specification factors, the insulation needed to be delivered to site in line with a tight schedule of works; an issue that was more complex than usual because it was set against a backdrop of heightened demand for construction products such as insulation.  Meeting the brief With this in mind, Sir Robert McAlpine Ltd approached its Strategic Supply Chain Partner, Knauf Insulation, to discuss the best available solutions for the Hockley Mills car park. Knauf Insulation’s Project Specification Team conducted U-value calculations and recommended that 130mm Rocksilk® Soffit Linerboard would meet the three critical performance requirements of the brief. Manufactured from rock mineral wool, Rocksilk® Soffit Linerboard is designed to insulate structural soffits in applications such as open-sided car parks. It has a thermal conductivity of just 0.034 W/mK, so will deliver the stipulated 0.16 W/m²K U-value required for the separating floor. It is non-combustible with the best possible Euroclass A1 reaction to fire classification, so will not add to the development or spread of fire should it occur. This means it is ideal for enhancing the fire safety of buildings of any height.  Rocksilk® Soffit Linerboard also has excellent sound absorption characteristics, so will help to reduce the transfer of noise from the car park to the properties above. Additional advice and support Once the product had been determined, the Knauf Insulation Project Specification Team provided details about the choice of finish available. Sir Robert McAlpine Ltd opted for Rocksilk® Soffit Linerboard Standard, which has a black tissue face finish. The Project Specification Team also advised on the required fixing pattern and set up meetings with their fixing partner who provided technical support such as pull-out value calculations. When it was time for Sir Robert McAlpine Ltd to order the insulation for Hockley Mills, there were high levels of demand across the whole construction sector causing significant challenges in obtaining materials. Knauf Insulation worked closely with distributor CCF to ensure the insulation was delivered to site in full within the required time frame. Wider benefits of Rocksilk® Soffit Linerboard Standard Rocksilk® Soffit Linerboard Standard has been designed for ease of correct installation. Its enhanced rigidity means it can be quickly manoeuvred into place. Once in position, the mineral wool adapts to the substrate preventing gaps that can reduce thermal, fire and acoustic performance.  Rocksilk® Soffit Linerboard Standard also contributes to the building’s sustainability credentials. It is manufactured with ECOSE® Technology, Knauf Insulation’s unique bio-based binder that contains no added formaldehyde or phenol. It is made from natural raw materials that are rapidly renewable, and is less energy-intensive to manufacture than traditional binders. Products made with ECOSE® Technology are soft to touch and easy to handle. They generate low levels of dust and VOCs, and have been awarded the Eurofins Gold Certificate for Indoor Air Comfort. This means they are kinder to the installers who use them too. By working with their Strategic Supply Chain Partner, Knauf Insulation, Sir Robert McAlpine Ltd received the technical and product advice they needed to choose the right soffit solution for Hockley Mills. A solution that will ensure residents are warm and comfortable, as well as helping to keep them and their homes and businesses fire safe. 

Knauf Insulation has the specification factorThe Learie Constantine Centre in Willesden, named after the former Trinidad and Tobago High Commissioner to the UK, and cricketing legend, Sir Learie Nicholas Constantine Kt MBE, is being redeveloped after 70 years. The new building will deliver 26 one, two and three bedroom apartments as well as a community centre.The project was designed by architects ECE on behalf of Wilmott Dixon, who have a supply chain agreement with Knauf Insulation. There were two factors for the insulation specification – fire safety and thermal performance.Fire safety is determined by the height and use of the building as well as the wall build-up. In this case, the Learie Constantine Centre is a five-storey residential building with an external wall build-up comprising both a brickwork façade and rainscreen cladding. This means the insulation used in the external walls must comply with changes to Approved Document B that ban the use of combustible material in certain types of external walls, such as rainscreen façade systems, of residential buildings between 11m and 18m high unless a full-scale fire test is undertaken.The second part of the insulation brief was thermal performance. To comply with Approved Document L, U-values of 0.13 W/m2K were required for the external walls, 0.13 W/m2K for the balcony and 0.14 W/m2K for the bin store.Meeting the briefWith this in mind, ECE consulted Knauf Insulation’s Project Specification Team, who recommended using 170mm Rocksilk® EWI Slab for the external walls, 270mm of Rocksilk® Soffit Linerboard Extra under the balcony and 200mm of DriTherm® Cavity Slab 32 in the bin store.All three products are non-combustible with the best possible Euroclass A1 reaction to fire classification, so will not contribute to the development or spread of fire, should it occur.Rocksilk® EWI Slab has a thermal conductivity of 0.036 W/mK and is designed to insulate rendered external walls, while Rocksilk® Soffit Linerboard is a specialist product for insulating structural soffits and has a thermal conductivity 0.034 W/mK. DriTherm® Cavity Slab 32 is a full-fill glass mineral wool insulation solution with a thermal conductivity of 0.032 W/mK.SustainabilityAs well as thermal and fire safety performance, Knauf Insulation products also contribute to sustainability. Glass mineral wool is lower in embodied carbon than other mainstream insulants.Both Rocksilk® Soffit Linerboard and DriTherm® Cavity Slab 32 are also manufactured with ECOSE® Technology, Knauf Insulation’s unique bio-based binder that contains no added formaldehyde or phenol. It is made from natural raw materials that are rapidly renewable, and is less energy-intensive to manufacture than traditional binders.Products made with ECOSE® Technology are soft to touch and easy to handle. They generate low levels of dust and VOCs, and have been awarded the Eurofins Gold Certificate for Indoor Air Comfort. This means they are kinder to the installers who use them too.Knauf Insulation’s glass and rock mineral wool insulation solutions had all the right ingredients to meet the brief for the Learie Constantine Centre. They will help to create a safe and comfortable environment for homeowners and leisure centre users alike. 

ChallengeTo insulate one of Marks and Spencer’s most carbon efficient premier stores with a holistic approach taken towards key sustainability factors such as water, carbon, biodiversity, the community, materials and waste to landfill.SolutionKnauf Insulation’s FactoryClad Roll 40 was utilised within the 11,000m2 multi-wave form standing seam roof, which was supplied by Euroclad to achieve an outstanding visual, functional and environmentally friendly element of the store design, plus achieving a BREEAM ‘Excellent’ rating. The number of BREEAM credits available from using Knauf Insulation’s Factory Clad Roll 40, played a part in its specification for Marks and Spencer’s flagship sustainable retail store at Cheshire Oaks.Gethin Williams, Euroclad’s Elite Systems Coordinator said: “FactoryClad Roll 40, in 280mm, has a 90/90 lambda value, a generic BRE Green Guide rating of A+ and has excellent thermal and acoustic properties. Thanks to these many characteristics, we thought it was perfect for this project, which resulted in it achieving the relevant BREEAM credits. Being lightweight, flexible and with a high tear strength, fitting was fast and error free, ensuring the thermal integrity was uncompromised.”Knauf Insulation’s FactoryClad Roll 40 is manufactured with ECOSE® Technology, has a thermal conductivity of 0.040W/mK and also has the highest possible Euroclass A1 reaction to fire classification when tested in accordance with BS EN 13501-1.In addition to this, Knauf Insulation’s mineral wool products with ECOSE Technology benefit from a revolutionary, bio-based, formaldehyde-free binder technology, based on rapidly renewable materials, instead of petro-based chemicals – delivering superior environmental sustainability and enhancing the environmental credentials without affecting the thermal, acoustic or fire performance. What’s more Knauf Insulation FactoryClad Roll 40 represents no known threat to the environment and has zero Ozone Depletion Potential and zero Global Warming Potential."Knauf Insulation FactoryClad Roll 40, in 280mm, has a 90/90 lambda value, a generic BRE Green Guide rating of A+ and has excellent thermal and acoustic properties. Thanks to these many characteristics, we thought it was perfect for this project, which resulted in it achieving the relevant BREEAM credits. Being lightweight, flexible and with a high tear strength, fitting was fast and error free, ensuring the thermal integrity was uncompromised."- Gethin Williams, Euroclad’s Elite Systems Coordinator

When the government instructed people to work from home during the Covid-19 pandemic, the gym where Wirral-based personal trainer Megan Hewitt worked closed down. So, Megan and partner Dan decided to build a fitness studio in their garden to allow her to conduct video personal training sessions during lockdown. To ensure the 6m x 3m timber frame building would be suitable for use all year round, it was essential to insulate the roof and walls.The couple researched various types of insulation online and narrowed it down to Mineral Wool because of its thermal performance and fire safety. They had three other considerations: it had to be good at blocking noise, have excellent sustainability credentials, and be easy to install, as they planned to fit it themselves.Just one product for all applicationsTheir research showed that Knauf Insulation 50mm and 70mm OmniFit Slab ticked all the boxes. It is a multi-application slab, meaning the couple didn’t need to purchase separate products for the roof and walls. What’s more, it offers a higher level of thermal performance than alternative versatile slabs on the market.It is manufactured from Glass Mineral Wool and is non-combustible with a Euroclass A1 Reaction to Fire Classification, meaning it will not add to the development or spread of a fire should it occur.Keeping quietAs any exercise fanatic knows, a good workout needs a strong soundtrack and Megan wanted to motivate clients without becoming a noisy neighbour. OmniFit Slab provides excellent levels of acoustic performance thanks to its open fibre structure that absorbs sound waves.Insulation that doesn’t cost the earthSustainability was another important factor for the couple. Like all of Knauf Insulation’s Glass Mineral Wool insulation, it is manufactured from up to 80% recycled content, mostly used glass bottles and jars that would otherwise go to landfill.It is also manufactured with ECOSE® Technology, Knauf Insulation’s unique bio-based binder, which contains no added formaldehyde or phenol. ECOSE® Technology is made from natural raw materials that are rapidly renewable and is 70% less energy-intensive to manufacture than traditional binders, so it is more environmentally-friendly.Products made with ECOSE® Technology are soft to touch and easy to handle. They generate low levels of dust and VOCs (volatile organic compounds) and have been awarded the Eurofins Indoor Air Comfort Gold Standard.Its softness was a benefit that Megan noticed during installation. She said: “I remember helping my Dad with our ‘old-school’ Mineral Wool loft insulation when I was younger and it was horrible, it irritated my skin for 24 hours after. But the OmniFit was fine – there was no irritation whatsoever.”Installation was no sweatA tight fit between joints is essential to eliminate gaps that can reduce thermal and acoustic performance, but with some types of insulation it can be difficult to achieve the high quality installation required. OmniFit Slab is manufactured to provide friction fitting to ensure all joints are sealed correctly. Despite having no previous experience, Megan, Dan and a friend fitted the 40m2 OmniFit Slab themselves over the course of a day.“Before fitting the insulation, we watched an installation video on YouTube,” said Megan. “We followed the techniques shown and it was really easy to install. We had no problems at all.”“I’m delighted with the finished result. When the fitness studio was finished, we kept turning up the stereo to see whether the insulation really was soundproof – even at full blast, you couldn’t hear the music outside. It’s amazing.”“Before we put the insulation in, I was exercising in winter gear with the radiator on full – now the studio is lovely and warm. I’m back in vests and I haven’t had to put the heating on at all.”Thanks to Knauf Insulation OmniFit Slab, Megan and her clients can enjoy a high energy workout in a warm, safe environment – without disturbing her neighbours. What’s more, the insulation is sustainable and will ensure the studio’s energy consumption and carbon emissions are low over its lifetime. Note: Megan, Dan and her friend maintained social distancing guidelines during the insulation install. Megan continues to follow government guidelines for the operation of gyms and exercise facilities, conducting her sessions online when in-person training is not possible.

Middlewood Locks is a prestigious 25-acre mixed-use regeneration scheme of Salford’s canal district. The first development phase included the construction of Quarry, an eight-storey building combining ground floor commercial space, luxury apartments and an undercroft car park for residents. It was the insulation for this car park that threw up a challenge for sub-contractor Horbury Building Systems. A complex underdrawing method had been specified, comprising the installation of timber battens, non-combustible mineral wool insulation and a separate soffit insulation over the top. Installation would be extremely labour-intensive, so Horbury Building Systems consulted Knauf Insulation about whether it could provide an alternative that would meet the thermal performance and fire safety requirements, but also be easy to install. Knauf Insulation’s Technical Support Team reviewed the specification and recommended 185mm Rocksilk® Soffit Linerboard Extra to achieve the required 0.18 W/m2K U-value.  Rocksilk® Soffit Linerboard Extra is a Rock Mineral Wool insulation slab bonded to a 6mm off-white weather resistant facing board which provides a two-in-one aesthetic and thermal solution. It has a low thermal conductivity of just 0.034 W/mK and is designed for use as an insulated underlining solution in semi-exposed environments. The off-white cementitious particle board reflects light which makes it ideally suited for use in car parks. As well as thermal performance, Rocksilk® Soffit Linerboard Extra is non-combustible. It has the best possible Euroclass A1 reaction to fire classification, so it will not contribute to the development or spread of a fire should it occur. This is important because car parks can contain large quantities of a potential propellant – petrol. So the insulation will help to ensure the fire safety of the rest of the building.   Rocksilk® Soffit Linerboard Extra also has good sound absorption characteristics so it provides high levels of sound reduction. This reduces noise from the car park, minimising disruption for the people living and working in the premises above. As well as meeting the specification, Rocksilk® Soffit Linerboard Extra has been enhanced to add rigidity and is easy to install. The board is simply placed onto the concrete soffit and fixed into position with five drillscrews. This reduced the installation method from three separate phases to just one, saving Horbury Building Systems time and associated labour costs. Stephen Hampshire, Contracts Manager at Horbury Building Systems said: “We found the panels easy to install. Firstly, we marked and drilled the fixing points at bench level. Next, we held the panels in place to the underside of the concrete – although the panels are lightweight ‘this is a two-handed operation’ – then we drilled through and fixed.”  “We took care in lining the panels together when installing it against the soffit and with some minor tweaking up and down we got a nice flush finish.” Being able to align the panels exactly is not only important for ensuring a good finish. It also means that the slabs will butt tightly together, reducing unintended air gaps which can reduce thermal, fire safety and acoustic performance.  The insulation was supplied to the Middlewood Locks construction site by distributor Galaxy Insulation.  Thanks to Knauf Insulation’s Rocksilk® Soffit Linerboard Extra, the underlining of the car park at Middlewood Locks was easy to install, is aesthetically pleasing, and provides complete thermal, fire safety and acoustic performance.

ChallengeContractors Guaranteed Asphalt (GA) faced a unique conundrum regarding the insulation of the roof of the O2 Arena, the centre piece on the site of the former Millennium Dome and the first purpose-built music venue in London since The Royal Albert Hall in 1871.As the area required superior acoustic properties, a rock mineral wool product was the obvious solution, however the split-level roof form of the construction meant that loose mineral wool fibres were visible in the surrounding airspace. This is where Knauf Insulation’s technical expertise became invaluable! Knauf Insulation was able to specify a bespoke white-tissue-faced Krimpact product which entrapped the loose fibres.SolutionKnauf Insulation supplied over 100 tonnes of their Rocksilk® Flat Roof Slab Extra at 150mm (2x75mm), a consistent, high density rock slab with superior impact and compression resistance. This material is designed to offer not only the acoustic performance required by such a venue, but also good thermal resistance and an excellent fire rating classification (Euroclass A1 non-combustible, the highest level possible). The white-tissue-faced product was suitable to be exposed to the elements, and later sprayed with a grey solar reflective paint to seal the surface and enable the product to camouflage into its environment.To make the project even more complicated, the cranes used in the production did not fit under the existing structure of the Dome which meant that the roof had to be constructed at ground level and lifted into its final position. This was no problem for Knauf Insulation thanks to its innovative Supakube delivery system, which meant the product could be delivered to the correct area of the project with minimum effort. Supakube uses advanced compression technology and strong packaging materials, which ensures the product is not only easy to store but can be delivered more efficiently saving time and reducing carbon emissions from delivery vehicles as more product can be loaded onto each lorry.

‘Living lab’ created for tomorrow’s sustainability engineers The New Model Institute for Technology and Engineering’s (NMITE) Skylon campus is unique for many reasons. Created by a cohort of young designers, the campus building is biophilic, an exemplar of advanced timber construction techniques and a ‘living lab’, as well as being an educational space. Knauf Insulation products were used in the bespoke, timber frame wall panels constructed offsite by specialists Taylor Lane. Experimental and high performing The New Model Institute for Technology and Engineering (NMITE) is a higher-education provider that has been created from the ground up by its founders, teachers, donors, and a cohort of young designers. Its goal is to give young people a path to becoming integrated engineers that are ‘sustainability conscious’ and ready to find solutions for achieving net zero. NMITE needed a campus that facilitated its unconventional style of teaching and reflected the aspirations of the institution. Sustainability was an important goal, as was using biophilic design – used to increase the building occupants’ sense of connection to the natural environment. As well as making the campus itself an object for students to learn more about timber construction, NMITE wanted the site to be a ‘living lab’. Sensors would be used to monitor the campus’ structural, acoustic, and thermal performance, with the intention of sharing this data with the industry to develop insights. This meant creating a building that was as high performing as it was experimental. Educational panel Knauf Insulation’s products were used for the pre-fabricated panels supplied for the construction of the building. Taylor Lane built 20 panels using a selection of non-standard materials and techniques specified by NMITE to demonstrate different approaches to students. Although each panel was unique, they all had a 240mm cavity that was insulated with OmniFit® Slab 35. The insulated panels were then craned into position before being attached to the building. Some were attached to the cross-laminated timber (CLT) frame, others to steel, so that students could readily observe even more varied approaches to construction. Sustainable performance OmniFit® Slab 35 is a glass mineral wool slab designed for use in both timber and steel frame constructions. Its thermal conductivity is 0.035 W/mK, and OmniFit® Slabs also provide sound insulation, a crucial feature for a busy workshop and educational space. “We chose OmniFit® Slab 35 for this project for several reasons. Its thermal and acoustic performance was important, but we also knew that, in the spirit of the project, we wanted to use materials that were sustainable. Glass mineral wool can be made from recycled glass and has low embodied carbon,” explained Paul Harris, Contracts Director. Knauf Insulation’s glass mineral wool is manufactured in the UK at its plant in St Helens. Up to 80% of the glass content comes from recycled glass collected locally and processed in the Veolia plant opposite the factory. About 60,000 tonnes are processed every year, and through smart compression packaging and local production, about 375,000 road miles are saved on transport annually. These factors contribute to glass mineral wool having the lowest levels of embodied carbon of any mainstream insulation material. Centre for Advanced Timber Technology The campus building is now home to students of the Centre for Advanced Timber Technology (CATT) and the Centre for Automated Manufacturing (CAM).  “Coming to the campus is a real highlight of the course, I love the unique design and the biophilic features are inspiring,” explained a CAM engineering student. NMITE’s vision of an experimental, educational, sustainable, biophilic and functional campus has blossomed, thanks to the work of contractors Speller Metcalfe and Taylor Lane. Knauf Insulation’s OmniFit® Slab 35 has played a small but significant role, providing thermal and acoustic performance using a sustainable material, for an institution dedicated to teaching environmentally conscious engineers. 

The Oak Cancer Centre at The Royal Marsden’s Sutton site is a state-of-the-art research and treatment facility, designed to bring the hospital’s 400-strong research team and its clinical care facility together under one roof. Specialist brickwork contractors, Lesterose Builders, were appointed by main contractor ISG to design and build the 2,800m2 masonry façade. As a result, they were responsible for ensuring the façade complied with the relevant thermal and fire safety regulations. The time and cost challenge The architect’s specification named a rock mineral wool product, but when Sam O’Keefe, Commercial Manager at Lesterose Builders, tried to place the order, there were two problems. He explained: “The first issue was availability – there was an eight to ten week lead time due to materials shortages. And the second issue was cost. We discovered the original insulation manufacturer had two planned price increases, and the extended lead time and phased delivery schedule meant that the Oak Cancer Centre project would be hit by both.” These two issues would not only delay the build, but would push it significantly over budget. So Lesterose Builders needed another insulation solution. Meeting the specification Lesterose Builders turned to Knauf Insulation, a fellow member of the Association of Brickwork Contractors (ABC). Knauf Insulation’s sales team looked at the specification and was able to offer an equivalent – 200mm Rocksilk® RainScreen Slab.  Rocksilk® RainScreen Slab is a rock mineral wool insulation product with a thermal conductivity of just 0.034W/mK, which meant it would meet the U-value of 0.21W/m2K. It is also non-combustible with Euroclass A1 reaction to fire classification, which means it will not contribute to the development or spread of fire should it occur. It is British Board of Agrément (BBA) certified for masonry façades at any height as well as for the broadest range of build-ups of any rainscreen solution on the market. This meant Rocksilk® RainScreen Slab was suitable for use in the Oak Cancer Centre because it complies with building regulations that ban the use of combustible materials in the walls of relevant buildings over 18m tall. In addition to fire safety and thermal performance, Rocksilk® RainScreen Slab offers excellent sound reduction characteristics. Crucially, Knauf Insulation was able to meet both the schedule and cost parameters for the project. “Once we had confirmation that Knauf Insulation could match the specification and deliver to the planned timescales and budget, it was then a case of getting the architect’s approval. This went extremely smoothly. We just made a technical submittal with the datasheets and environmental product declaration (EPD) and Rocksilk® RainScreen Slab was approved for use without any queries.” Ease of installation The seven-full loads of insulation were purchased through Parker Building Supplies. These were delivered to the site in eight phases in line with the schedule of works. The product is designed to be easy to install correctly. Superior robustness and durability mean it can be manoeuvred easily into place. And unlike some competitor products, it can be installed with either face of the slab against the substrate, speeding up installation and preventing incorrect installation. Furthermore, the natural flexibility of rock mineral wool means it adapts to minor imperfections in the substrate, while slabs knit together when tightly butted, eliminating air leakage that could reduce thermal and acoustic performance. Rocksilk® RainScreen Slab is also manufactured with ECOSE® Technology, Knauf Insulation’s unique bio-based binder that contains no added formaldehyde or phenol. It is made from natural raw materials that are rapidly renewable, and is 70% less energy-intensive to manufacture than traditional binders, so it is more environmentally friendly. Products made with ECOSE® Technology generate low levels of dust and VOCs (volatile organic compounds) and have been awarded Eurofins Indoor Air Comfort (Gold) certification. Construction work is known for its challenges, particularly around budgets and schedules – but thanks to Knauf Insulation’s Rocksilk® RainScreen Slab, Lesterose Builders was able to overcome both these issues and meet the required specification factors for the Oak Cancer Centre. 

Built from traditional stone and slate, Preston Springs, a four bed home in Leyburn, North Yorkshire, may look like a typical new-build property, but it is far from it. Designed by architects LEAP, Preston Springs is a Passivhaus, meaning it is ahead of its time in terms of air quality, comfort and reduced energy use. It is one of the only properties of its type in the local area, with just over 1,000 Passivhaus properties in the whole of the UK. Passivhaus is a voluntary standard for designing and building very low energy properties that offer high levels of comfort for their occupants. To achieve this, the levels of air tightness and thermal performance far exceed those mandated by building regulations. To meet planning constraints, Preston Springs has been built using a conventional cavity wall construction. The 300mm cavity was fully-filled using two layers of 150mm Knauf Insulation DriTherm® Cavity Slab 34. Manufactured from Glass Mineral Wool, Knauf Insulation DriTherm® Cavity Slab is specifically designed for cavities and uses a water repellent additive to prevent water ingress, making it ideal for its exposed location close to the Yorkshire Dales.Knauf Insulation DriTherm® Cavity Slab 34 was chosen over rigid board insulation. Its structure meant the stone masons could cut and fit the insulation easily on site to ensure it fully-fills the cavity, touching both leaves continuously. This prevents undesirable air gaps that reduce thermal performance. It is worth noting that masonry construction with partially-filled cavities are particularly prone to air gaps between insulation boards or breaks in contact between the insulation and the wall surface.Secondly, because detailing at junctions between the building elements and the openings meant thermal bridging was virtually eliminated, a more cost effective insulation specification could be chosen. Principal architect Mark Siddall was confident that Knauf Insulation DriTherm® Cavity Slab 34 would deliver the 0.1 W/m2K U-Value required to help the project achieve Passivhaus certification. For the loft, Supafil® Loft Blowing Wool was specified after extensive consultation with Knauf Insulation’s Technical Support Team. While Supafil® Loft is very popular in Scandinavian countries, it is not widely used in the UK. However, Siddall believes that blown insulation has a distinct advantage over other insulation types when working towards very high levels of thermal performance. He said: “The advantage of Supafil® Loft insulation is that it can get it into all the nooks and crannies very quickly and easily. This makes it a low-cost solution as far as labour is concerned because installers don’t have to cut and scribe around individual trusses at 400 and 600mm centres – something that would take a huge amount of time. By avoiding these air gaps, the roof can be expected to deliver the thermal performance that was specified.”It was not just the use of Supafil® Loft that was unusual on the Preston Springs project, but its depth; 700mm of Supafil® Loft was installed, delivering a U-value of 0.06, which Siddall believes makes it one of the most highly-insulated lofts in the UK.Siddall explains that to achieve Passivhaus standard, installation is hugely important. He said: “The only way to close performance gaps is through high quality workmanship. I have used the same construction team on several projects. I ensured that the installer had received the necessary training on how to install the Supafil® Loft insulation correctly, so I had the quality assurance that it would perform as specified in practice.”Steve Wise, Programme and Product Development Manager at Knauf Insulation added: “It is always exciting to work on projects that feature products not commonly used in the UK or in applications that differ from the norm, such as the 700mm Supafil® Loft at Preston Springs.“Passivhaus projects allow us as manufacturers to explore what is possible. Preston Springs demonstrates how environmentally-focused design, high performance products and high quality installation can deliver and meet even the strictest thermal standards in a real-world environment.”Typically, Passivhaus properties achieve a 75% reduction in space heating requirements, compared to a standard UK new build. While monitoring is ongoing, anecdotal evidence from the owners show that Preston Springs is performing as designed, maintaining a temperate climate throughout the year. During ‘The Beast from the East’ the internal temperature was a reported 19°C without heating, while the external temperature plummeted to -6°C. Furthermore, the owners report they are delighted with the low energy bills thanks to the very high thermal performance of the insulation combined with the heat recovery system.

The Priscilla Bacon Lodge in Norfolk is a new £12.5 million hospice that will provide state-of-the-art palliative care for 24 patients alongside day care facilities, a wellness centre, gym and community hub for those being cared for at home. It will also be used for education and research into palliative and end-of-life care. The facility, designed by LSI Architects and delivered by Morgan Sindall Construction, features both traditional masonry cavity walls, and a masonry rainscreen façade.  Meeting the brief At just two stories high, the building doesn’t fall under building regulations that ban combustible materials in the wall build-up. But even so, combustibility was a key factor when it came to specifying the insulation. Jordan Armstrong, Associate at LSI Architects explained: “As a practice we always try to minimise fire risk, especially for a project like The Priscilla Bacon Lodge, which will house extremely vulnerable people. So, it was essential that the materials we used were non-combustible, which meant mineral wool insulation was the only solution. “We regularly use Knauf Insulation products, so we specified DriTherm® Cavity Slab 32 for the cavity walls because it’s a high-performing glass mineral wool insulation that we expected could meet our required 0.16 W/m2K U-value. We were also keen to specify their Rocksilk® RainScreen Slab for partially filled cavity walls because then we would have one manufacturer for the whole build, and we think the products will work well together.” DriTherm® Cavity Slab 32 is full-fill insulation solution with a thermal conductivity of 0.032W/mK. While Rocksilk® RainScreen Slab for partially filled cavity walls is a rock mineral wool product with a thermal conductivity of 0.034W/mK. Both products are BBA certified for the application. In addition to non-combustibility and thermal performance, both products also offer sound reduction characteristics. Ease of installation Both DriTherm® Cavity Slab 32 and Rocksilk® RainScreen Slab contain a water repellent additive that preserves the integrity of the slabs while they are exposed during construction.  The products are also designed to be easy to install correctly. They are sized to suit standard centres for installation between wall ties or brick restraint systems. Slabs are robust so they can be manoeuvred into place while maintaining the flexibility required to adapt to minor imperfections in the substrate to prevent gaps that reduce thermal, fire and acoustic performance.  Lastly, they are both manufactured using ECOSE® Technology, Knauf Insulation’s unique bio-based binder, which contains no added formaldehyde or phenol. It is made from natural raw materials that are rapidly renewable, and is 70% less energy-intensive to manufacture than traditional binders, so it is more environmentally friendly. The product is soft to touch, easy to handle, and generates low levels of dust and VOCs. So, when it came to specifying the insulation for the Priscilla Bacon Lodge, Knauf Insulation’s DriTherm® Cavity Slab 32 and Rocksilk® RainScreen Slab for partially filled cavity walls ticked all the boxes. 

“We needed extremely detailed U-value calculations, and Knauf Insulation is one of the best at supplying these”, Paul Mann, Sales & Pre-Construction Director, TAC Projects.3,000m2 of Knauf Insulation Rocksilk® RainScreen Slab is providing essential comfort and fire safety for vulnerable residents in a new development on a challenging site.Quantock House, Taunton is a new collection of 88 assisted living apartments set over nine storeys in a prime position at the heart of Somerset’s county town. It is the latest development from Platinum Skies, part of the Affordable Housing and Healthcare Group (AHH). Specialist contractor TAC Projects was tasked with the technical design and overall delivery of the façade.There were two essential considerations for the insulation specification. The first was that it had to be non-combustible, with a Euroclass A1 reaction to fire classification. “We never use combustible materials on any residential façade, regardless of height” explained Paul Mann, Sales & Pre-Construction Director, TAC Projects. “This is especially important in developments with vulnerable residents.”The second was thermal performance. The façade had to achieve a U-value of 0.18W/m2K, but with a complex design including acute angles between elevations and an undercroft car park, detailed calculations would be needed to support the specification. This was not just for best practice; to insure the building, the NHBC insisted on detailed supporting data for all products used in its construction.“The original specification from AAH’s architect was for Rock Mineral Wool. Our need for more robust U-value calculations, among other reasons, led us to choose Knauf Insulation Rocksilk® RainScreen Slab” said Paul. “That meant we were able to get 3D U-value calculations from its Technical Support team”.3D U-value calculations provide a much more detailed and accurate model of a building’s thermal performance. They give contractors, architects and third parties valuable reassurance that the interactions between different building elements have been properly considered, such that the calculations will more accurately reflect the energy efficiency of the building in the real world.Rocksilk® RainScreen Slab is a non-combustible Rock Mineral Wool insulation that offers exceptional thermal and acoustic performance. It achieves Euroclass A1 reaction to fire classification, and is BBA certified for the broadest range of build-ups of any rainscreen solution on the market.It is designed to be easy to install correctly. Slabs are robust enough for easy manoeuvrability, but capable of flexing to adapt to imperfections in the substrate and to interlock when butted together. This is critical as it prevents the air gaps that can occur when using other, more rigid types of insulation; gaps which can compromise thermal, fire or acoustic performance.Rocksilk® RainScreen Slab is also manufactured with ECOSE® Technology, Knauf Insulation's unique bio-based binder that contains no added formaldehyde or phenol. It is made from natural raw materials that are rapidly renewable and is 70% less energy-intensive to manufacture than traditional binders, so it is more environmentally-friendly. Products made with ECOSE® Technology are soft to touch and easy to handle. They generate low levels of dust and VOCs, and have been awarded the Eurofins Gold Certificate for Indoor Air Comfort.In addition to the 3D U-value calculations, the project required an extra level of service and logistical support. With no storage space on site, and only room for one lorry at a time, deliveries had to be meticulously planned to keep the job running smoothly. Distributor CCF, who supplied the insulation, worked closely with TAC Projects to schedule deliveries in line with their plan of works.“Our business is all about trust” continued Paul. “AAH is trusted by its customers to provide safe and warm homes. We’re trusted by them to build non-combustible, energy-efficient façades. And in turn, we trust Knauf Insulation to give us the innovative products and service we need to do that.”Thanks to these trusted relationships, the residents at Quantock House will enjoy their new homes in warmth and comfort, with the peace of mind that comes from knowing they are built using sustainable, non-combustible materials.

ChallengeWork is underway to create a new theatre that will transform the existing 1932 Royal Shakespeare Theatre whilst retaining the original Art Deco and Victorian elements of the building. Due for completion during 2010, the theatre will give artists and audiences alike the best environment in which to perform and enjoy Shakespeare with improved public spaces both inside and surrounding the theatre.The challenge for the project design is to blend the key aspects of the existing buildings with the new theatre designs. Specialist roofing contractor, Varla (UK) Limited were awarded the contract to design, manufacture and install the zinc standing seam roof and wall package. Varla (UK) Limited challenged Knauf Insulation to propose a solution to meet the demanding specification for this unique project.SolutionKnauf Insulation provided detailed ongoing technical support during the design stages of the project and proposed solutions based on the results of unique three-dimensional heat loss calculations. The unique 3-D calculation support service, provided by the Technical Advisory Centre, was an integral part of the product specification process to ensure that the exact thickness recommendations were proposed in order to meet the project’s specific U-value requirements.Knauf Insulation were able to provide a solution that met all of Varla’s insulation requirements by using 160mm of Knauf Insulation FactoryClad Roll 32. This is a flexible, lightweight roll of resilient Glass Mineral Wool with exceptionally high tear strength and a thermal conductivity of just 0.032 W/mK.In addition, Knauf Insulation FactoryClad Roll 32, recommended for this project, is manufactured from Glass Mineral Wool, which is ideal for limiting the spread of fire since it holds a Euroclass A1 reaction to fire classification for non-combustibility. The product will not burn, will not give off toxic smoke nor will it suddenly ignite in a fire due to ‘flashover’. For public buildings such as this, superior fire performance is crucial.

Salamander Street is a mid-market rent initiative that provides high quality affordable homes in the heart of Leith, Edinburgh. It comprises 199 flats and maisonettes across six storeys of accommodation, constructed over a basement car park.It was designed by 7N Architects, which specified Knauf Insulation’s 50mm Rocksilk® RainScreen Slab to insulate the ventilated façade. They chose this product because it met the brief’s two critical performance factors: thermal performance and fire safety.It is a Rock Mineral Wool insulation slab with a thermal conductivity of 0.034W/mK, so it delivers the required U-value of 0.16 W/m2K. It is non-combustible with the best possible Euroclass A1 reaction to fire classification and is BBA certified for use in a wide range of build-ups in high rise buildings. This means it complies with Building Regulations in Scotland that restrict the use of combustible materials on most buildings over 11m.The Salamander Street development was overseen by main contractor Cruden Building East with sub-contractor Soundtex responsible for installing the insulation.It was constructed using an Ancon Brick Restraint System. Ancon has undertaken independent third-party tests to demonstrate that its restraint system does not require a compression sleeve when used in conjunction with Rocksilk® RainScreen Slab under 180mm thick. This provided a huge saving in labour costs for Soundtex as fasteners are usually inserted into compression sleeves by hand.Throughout the build, Knauf Insulation’s Specification Team attended regular project meetings and conducted site visits to check the quality and progress of installation. Rocksilk® RainScreen Slab is optimised for ease of installation and improved robustness, making it easy to manoeuvre into position. At Salamander Street, the Specification Team noted the uniformity of installation and perfectly staggered joints. This is important because it ensures there are no gaps, which could reduce thermal and acoustic performance – a common issue with rigid foam board insulation.Rocksilk® RainScreen Slab is manufactured with ECOSE® Technology, Knauf Insulation's unique bio-based binder that contains no added formaldehyde or phenol. It is made from natural raw materials that are rapidly renewable and is 70% less energy-intensive to manufacture than traditional binders, so it is more environmentally friendly.Products made with ECOSE® Technology are soft to touch and easy to handle. They generate low levels of dust and VOCs and have been awarded the Eurofins Gold Certificate for Indoor Air Comfort.The Rocksilk® RainScreen Slab insulation was installed in conjunction with Knauf Windliner sheathing board for maximum performance.Thanks to Knauf Insulation, the residents of Salamander Street will enjoy warm, cosy homes that meet the highest standards of fire safety.

Entering a building is usually the only way to find out what takes place inside. But that’s not the case with the Manchester Metropolitan University’s new School of Digital Arts (SODA). It acts as a giant canvas to illuminate digital content produced by students, thanks to an LED rainscreen façade on its northern face. The five-storey, 5,200m2 SODA building is adjacent to the Manchester School of Art and will provide space for a digital innovation and User Experience (UX) lab, film studios, green screens, edit suites, sound, music and production studios; alongside a screening room and gallery space. Like all rainscreen façade projects, the SODA building needed insulation to meet the required thermal, fire safety and acoustic performance, but the LED façade added complexity to the specification. The chosen rainscreen panels were perforated with small holes to allow the lights to shine through – but this also meant the insulation could be seen from certain angles, so the insulation needed to look aesthetically pleasing too. During the design process, architects Feilden Clegg Bradley Studios had specified Knauf Insulation’s Rocksilk® RainScreen Slab for the project. It is non-combustible with a Euroclass A1 reaction to fire classification, so complies with building regulations that ban combustible insulation on certain buildings over 18m tall in England and Wales.  Rocksilk® RainScreen Slab also has a thermal conductivity of 0.034 W/mK so could meet the U-value of 0.19 Wm2K. And thanks to its sound absorption characteristics, critical for low mass rainscreen structures, it will help create a quieter space for the students. The principal contractor Kier Construction had tasked specialist façade contractors Maple Sunscreening with determining the required thickness and aesthetics. So they contacted Knauf Insulation to discuss the best solution.  Knauf Insulation’s Technical Support Team undertook 3D U-value calculations and confirmed that a 150mm slab should be used for the project.  What’s more, Rocksilk® RainScreen Slab is manufactured with ECOSE® Technology, Knauf Insulation's unique bio-based binder that contains no added formaldehyde or phenol. This gives Knauf Insulation’s mineral wool its unique brown colour, so the insulation won’t stand out behind the perforated rainscreen panels. It also makes it soft to touch, easy to handle and generates low levels of dust and VOCs. As a result, products made with ECOSE® Technology have been awarded the Eurofins Gold Certificate for Indoor Air Comfort. Rocksilk® RainScreen Slab is designed to be easy to install correctly. Slabs are robust which makes them easy to manoeuvre into place. Once in position, they butt tightly together and adapt to any imperfections in the substrate. This prevents unintended air gaps that can compromise thermal, fire safety or acoustic performance. Using Rocksilk® RainScreen Slab was the optimal solution for the SODA building providing both the high thermal, fire safety and acoustic performance demanded of modern buildings. And thanks to its unique brown colour, the mineral wool insulation won’t be a distraction, instead acting as the perfect backdrop for the dazzling LED light displays created by the students. 

Creating a Passivhaus home Balancing sustainability and style, Sort Trae is the culmination of a retired architect’s vision for a home and creative space that blends into a South Yorkshire hillside. HEM Architects helped the client to bring this dream to life, using Knauf Insulation’s glass mineral wool insulation to achieve the incredibly high Passivhaus standards for energy efficiency. Low carbon and high comfort The client envisioned a sustainable build using Passivhaus, a voluntary standard for designing and building properties with very low energy consumption, that offer high levels of comfort for their occupants. To achieve this, the levels of air tightness and thermal performance far exceed those mandated by building regulations. FrameTherm® Slab 32 was friction-fitted within the 140mm thick timber frame walls on the first floor, while DriTherm® Cavity Slab 32 was used to fill the stone-clad masonry cavity walls on the ground floor.  “We try to specify fully filled masonry cavity walls where possible, sometimes up to 200mm wide, to maximise the use of mineral wool insulation. It pays dividends for the client”, explained Liam Seaman, Architectural Technologist for HEM Architects. Thermal performance is critical to the Passivhaus approach. The FrameTherm® Slab 32 provided a calculated U-value of 0.137 W/m2K in combination with the black timber frame wall and cladding. For the masonry cavity wall on the ground floor, a fractionally higher U-value of 0.138 W/m2K was achieved using thermally broken wall ties and DriTherm® Cavity Slab 32. This has contributed to Sort Trae’s exceptional thermal efficiency. Because glass mineral wool is flexible and fibrous, slabs knit together and adapt to minor imperfections in the substrate. This tight fit contributed to an overall air change of 0.54 ach (air change per hour), comfortably below the Passivhaus standard of 0.6 ach, meaning the property is air-tight while still providing good ventilation. Sustainable practices Liam explained his reasons for choosing Knauf Insulation, “The alternative products are often oil-based and the application of these is outweighed by the environmental impact of their production and lifecycle.” Both FrameTherm® Slab 32 and DriTherm® Cavity Slab 32 are manufactured with ECOSE® Technology, Knauf Insulation’s unique bio-based binder that contains no added formaldehyde or phenol. The binder is made from natural raw materials that are rapidly renewable and is 70% less energy-intensive to manufacture than traditional binders. Knauf Insulation’s glass mineral wool insulation contains up to 80% recycled content, mostly glass bottles and jars. It is also compressed so more product can fit per pack or pallet, and less packaging is used. This means there’s more product per truck, resulting in fewer vehicles on the road, and less packaging per m2 of insulation. Achieving the Passivhaus standard In collaboration with HEM Architects and other suppliers, the client has created a stunning home and an inspiring set-up for her loom-weaving workshop. “It is general practice for us to specify Knauf Insulation as standard because we find the product information available to be really clear and useful”, Liam added. Knauf Insulation’s practical, detailed product information made it HEM Architects’ first choice to achieve the Passivhaus standard for thermal performance. 

SOYO Leeds is a £300 million mixed use scheme that creates a new neighbourhood adjacent to the city’s cultural quarter.Designed by DLG Architects for Caddick Construction and Moda Living, SOYO Leeds will comprise residential and student accommodation, a hotel, restaurants, bars and offices. And at the heart of this new cultural centre is 10,000m2 of Knauf Insulation Rocksilk® RainScreen Slab.During the construction of the scheme’s 515 hotel-style rental apartments, rainscreen contractor Axis Envelope Solutions needed to source suitable, compliant insulation. So, it consulted Knauf Insulation, the UK’s only manufacturer of Glass and Rock Mineral Wool insulation, about which solutions would meet the required thermal and fire performance specification.Knauf Insulation’s Specification Team reviewed the architect’s drawings which included a build-up featuring a steel top hat. The company’s Technical Support Team then undertook 3D U-value calculations completed in line with BS EN 10211 to ensure the finished building’s performance matched the initial design.Because 3D U-value calculations are done in-house, the team were able to turn around the complex calculations in the time frame required.Once the calculations had been performed, Knauf Insulation recommended 180mm Rocksilk® RainScreen Slab as the optimal solution to meet the thermal requirements of the build.As well as exceptional thermal performance, Rocksilk® RainScreen Slab is highly sound absorbent with excellent sound reduction capabilities. It is non-combustible with the best possible Euroclass A1 reaction to fire classification so will not contribute to the development or spread of fire should it occur. This means it meets the requirements of building regulations in England and Wales banning the use of combustible materials on all buildings over 18m. In addition, Rocksilk® RainScreen Slab is British Board of Agrément (BBA) certified for use in high rise buildings and for the broadest range of thicknesses and build-ups of any rainscreen solution on the market.Rocksilk® RainScreen Slab is manufactured with ECOSE® Technology, Knauf Insulation's unique bio-based binder that contains no added formaldehyde or phenol. It is made from natural raw materials that are rapidly renewable and is 70% less energy-intensive to manufacture than traditional binders, so it is more environmentally friendly.Products made with ECOSE® Technology are soft to touch and easy to handle. They generate low levels of dust and VOCs, and have been awarded the Eurofins Gold Certificate for Indoor Air Comfort.Rocksilk® RainScreen Slab has been designed for ease of use. It is robust which makes it is easy to manoeuvre into place and it can be installed either way round without compromising performance. The Mineral Wool knits together and adapts to imperfections in the substrate, preventing air gaps that compromise thermal, fire and acoustic performance.Thanks to the responsiveness of Knauf Insulation’s Specification and Technical Support Teams, Axis Envelope Solutions was able to keep to the tight schedule required. As a result, the new tenants of the luxury apartments at SOYO Leeds will be able to enjoy homes built to provide the highest level of thermal, fire safety and acoustic performance in the centre of the city’s newest cultural hub.

ChallengeThe St Vincent New Bridges’ project is run by St Vincent de Paul, a homeless hostel that supports people who need to have a place to live and that require help to develop their daily living skills. When the charity acquired the Grade II listed building, a major refurbishment plan was put into action, and St Vincent de Paul approached CRASH for help with materials and construction work.SolutionKnauf Insulation donated over 520m2 of 100mm Knauf Insulation Loft Roll 40 for the project, which was installed by Giraffe Building Services Ltd. The Glass Mineral Wool insulation product is extremely easy to handle and install, being lightweight and easily cut to size, benefiting the large project.BenefitsBy its nature, Knauf Insulation Loft Roll 40 is non-combustible and classified as Euroclass A1 to BS EN ISO 13501-1, a crucial requirement to any public building. Additionally, Knauf Insulation Loft Roll 40 has been manufactured with ECOSE® Technology which delivers superior environmental performance, as the binder technology is up to 70 per cent less energy intensive than traditional binders. The technology has been developed for Knauf Insulation’s Glass and Rock Mineral Wool products, enhancing their environmental credentials without affecting the thermal, acoustic or fire performance. Insulation products made with ECOSE® Technology contain no dye or artificial colours – the colour is completely natural.